THE WIND TURBINE

COMPONENTS AND OPERATION

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Table of contents page 4

Special Issue

BONUS INFO
Autumn 1999
THE NEVER ENDING STORY

THE WIND TURBINE

COMPONENTS AND OPERATION
BONUS-INFO is a newsletter for
customers and business associates of
the Bonus Energy A/S. This news-
letter is published once or twice a
year.

The first number came out in 1998,

and the newsletter has now been
published in four issues.
Each number has included an
article on the components and opera-
tion of the wind turbine. We have
received many suggestions and
requests that these articles should be
reprinted and published as a special
single issue.

Bonus is pleased to have hereby

fulfilled this request with the
publication of this special issue.

Author:
Henrik Stiesdal
Responsible under the press law

Lay-out/ Production:
Claus Nybroe

Translation:
John Furze, Hugh Piggott

Autumn 1999

BONUS ENERGY A/S

Fabriksvej 4, Box 170
7330 Brande
Tel.: 97 18 11 22
Fax: 97 18 30 86
E-mail: bonus@bonus.dk
Web: www.bonus.dk
4

THE WIND TURBINE

COMPONENTS AND OPERATION

The Aerodynamics of the Wind Turbine 5

Basic Theory ¥ The aerodynamic profile ¥ The aerodynamics
of a man on a bicycle ¥ Wind turbine blades behave in the
same way ¥ Lift ¥ The change of forces along the blade ¥
What happens when the wind speed changes ¥ The stall
phenomena ¥ Summary

The Transmission System 11

The hub ¥ Main shaft ¥ Main Bearings ¥ The clamping unit ¥
The gearbox ¥ The coupling

The Generator 15
Direct current (DC) ¥ Alternating current (AC) ¥ Three
phase alternating current ¥ Induction and electromagnetism ¥
The wind turbine generator as a motor ¥ Generator operation
¥ Cut-in ¥ Closing remarks

Control and Safety Systems 20

Problem description ¥ The controller ¥ Hydraulics ¥ Tip bra-
kes ¥ The mechanical brake
5
THE AERODYNAMICS OF THE WIND TURBINE
The three bladed rotor is the most
important and most visible part of the
wind turbine. It is through the rotor
that the energy of the wind is transfor-
med into mechanical energy that turns
the main shaft of the wind turbine.
We will start by describing why the
blades are shaped the way that they are
and what really happens, when the
blades rotate.
BASIC THEORY
Aerodynamics is the science and study
of the physical laws of the behavior of
objects in an air flow and the forces that
are produced by air flows.
Blade tip
Leading edge
Trailing edge
Blade root
Hub
The different components of a wind turbine blade
The front and rear sides of a wind
turbine rotor blade have a shape roughly
similar to that of a long rectangle,
with the edges bounded by the leading
edge, the trailing edge, the blade tip and
the blade root. The blade root is bolted to
the hub.
The radius of the blade is the distance
from the rotor shaft to the outer edge of
the blade tip. Some wind turbine blades
have moveable blade tips as air brakes,
and one can often see the distinct line
separating the blade tip component from
the blade itself.
If a blade were sawn in half, one
would see that the cross section has a
streamlined asymmetrical shape, with the
flattest side facing the oncoming air flow
or wind. This shape is called the bladeÕs
aerodynamic profile
THE AERODYNAMIC PROFILE
The shape of the aerodynamic profile is
decisive for blade performance. Even
minor alterations in the shape of the
profile can greatly alter the power curve
and noise level. Therefore a blade desig-
ner does not merely sit down and outline
the shape when designing a new blade.
The shape must be chosen with great care
on the basis of past experience. For this
reason blade profiles were previously
chosen from a widely used catalogue of
airfoil profiles developed in wind tunnel
research by NACA (The United States
National Advisory Committee for Aero-
nautics) around the time of the Second
World War.
NACA 44
NACA 63
Blade profiles
The NACA 44 series profiles were used
on older Bonus wind turbines (up to and
including the 95 kW models).
This profile was developed during the
1930Õs, and has good all-round proper-
ties, giving a good power curve and a
good stall. The blade is tolerant of minor
surface imperfections, such as dirt on the
blade profile surface.
The LM blades used on newer Bonus
wind turbines (from the 150 kW models)
use the NACA 63 profiles developed
during the 1940«s. These have slightly
different properties than the NACA 44
series. The power curve is better in the
low and medium wind speed ranges, but
drops under operation at higher wind
speeds. Likewise this profile is more
sensitive with regard to surface dirt.
This is not so important in Denmark,
but in certain climate zones with little
rain, accumulated dirt, grime and insect
deposits may impair and reduce
performance for longer periods.
The LM 19 blades, specifically
developed for wind turbines, used on the
Bonus 500 kW, have completely new
aerodynamic profiles and are therefore
not found in the NACA catalogue.
These blades were developed in a joint
LM and Bonus research project some
years ago, and further developed and
wind tunnel tested by FFA (The Aero-
dynamic Research Institute of The
Swedish Ministry of Defence).
THE AERODYNAMICS
OF A MAN ON A BICYCLE
To fully describe the aerodynamics of a
wind turbine blade could appear to be
rather complicated and difficult to under-
stand. It is not easy to fully understand
how the direction of the air flow around
the blade is dependent on the rotation of
the blade. Fortunately for us, air con-
stantly flows around everyday objects
following these very same aerodynamic
laws. Therefore we can start with the
aerodynamics of an air flow that most of
us are much more familiar with: A cyclist
on a windy day.
The diagrams (next page) show a
cyclist as seen from above. The diagrams
are perhaps rather sketchy, but with a
good will one can visualize what they
6
F F
v v
A B
Air flow around a man on a bicycle
represent. The diagram (A) on the left,
illustrates a situation, during which a
cyclist is stationary and can feel a side
wind ÒvÓ of 10 meters per second (m/s)
or roughly 22 mph (this is known as a
fresh breeze). The wind pressure will
attempt to overturn the cyclist. We can
calculate the pressure of the wind on the
windward side of the cyclist as roughly
80 Newton per square meter of the total
side area presented by the cyclist against
the wind. Newton, or N for short, is the
unit for force used in technical calculati-
on. 10 N is about 1kg/force (Multiply by
0.2248 to obtain lbf.). The direction of
the force of the wind pressure is in line
with the wind flow. If we consider that a
normal sized cyclist has a side area
facing the wind of about 0.6 square
meters, then the force F from the
pressure of the wind will be 0.6 x 80 N =
app. 50 N/m2.
In the center drawing (B) our cyclist
has started out and is traveling at a speed
ÒuÓ of 20 km/hour, equivalent to about 6
meters/second, still with a side wind ÒvÓ
of 10 m/s. We can therefore calculate the
speed of the resulting wind ÒwÓ striking
the cyclist, either mathematically or by
measurement on the diagram as 12 m/s.
This gives a total wind pressure of
100 N/m2. The direction of the wind pres-
sure is now in line with the resulting
wind, and this will give a force ÒFÓ on the
cyclist of about 60 N/m2.
In the right hand drawing (C) the
force of the wind pressure ÒFÓ is now
separated into a component along the
direction of the cyclistÕs travel and into
another component at a right angle to the
direction of travel. The right angled
force ÒFvÓ will attempt to overturn the
cyclist, and the force ÒFmÓ along the axis
of travel gives a resistance that slows
Fv
Fm
u
w
C right angle to the plane of rotation, which
down the cyclistÕs forward motion. The
size of ÒFmÓ is about 30 N/m2. This is
the resistance force that the cyclist must
overcome. A beginner, unused to cycling,
may wonder why the wind has changed
direction and a head wind is felt on
reaching speed. This beginner might well
ask Ò How can it be that I felt a side wind
when I was at rest and standing still,
could the wind have possibly changed its
direction? Ò But no, as any experienced
cyclist unfortunately knows, head wind is
an integral component of movement
itself. The wind itself has not turned. The
head wind is a result of speed, the faster
F F
Plane of rotation
v v
A B
Airflow around a blade profile, near the wing tip
one travels the more wind resistance one
experiences. Perhaps, as a famous Danish
politician once promised his voters, that
if elected he would insure favorable tail-
winds on the cycle-paths, things may
change in the future. However we others
have learnt to live with the head winds
resulting from our own forward
movement, whether we run, cycle or go
skiing.
WIND TURBINE BLADES
BEHAVE IN THE SAME WAY
Returning to the wind turbine blade, just
as in the situation for the cyclist, we can
observe the aerodynamic and force
diagrams in two different situations,
when the wind turbine is stationary and
when it is running at a normal operational
speed. We will use as an example the
cross section near the blade tip of a
Bonus 450 kW Mk III operating in a
wind speed ÒvÒ of 10 m/s.
When the rotor is stationary, as
shown in drawing (A) below, the wind
has a direction towards the blade, at a
is the area swept by the rotor during the
rotation of the blades. The wind speed of
10 m/s will produce a wind pressure of
80 N/m2 of blade surface, just like the
effect on our cyclist. The wind pressure is
roughly in the same direction as the wind
and is also roughly perpendicular to the
flat side of the blade profile. The part
of the wind pressure blowing in the
direction of the rotor shaft attempts to
bend the blades and tower, while the
smaller part of the wind pressure
blowing in the direction of the rotation
of the blades produces a torque that
attempts to start the wind turbine.
Once the turbine is in operation and
the rotor is turning, as is shown in the
Fa
Plane of rotation Fd
u
w
C
center diagram (B), the blade encounters
a head wind from its own forward
movement in exactly the same way as the
cyclist does. The strength of head wind
ÒuÓ at any specific place on the blade
depends partly on just how fast the wind
turbine blade is rotating, and partly how
far out on the blade one is from the shaft.
In our example, at the normal operating
speed of 30 rpm, the head wind ÒuÓ near
the tip of the 450 kW wind turbine is
about 50 m/s. The ÒmeteorologicalÓ wind
ÒvÓ of 10 m/s will thus give a resulting
wind over the profile of about 51 m/s.
This resulting wind will have an
effect on the blade surface with a force
 7
of 1500 N/m2. The force ÒFÓ will not be
in the direction of the resulting wind, but
almost at a right angle to the resulting
wind.
In the drawing on the right (C) the
force of the wind pressure ÒFÓ is again
split up into a component in the direction
of rotation and another component at a
right angle to this direction. The force
ÒFaÓ at a right angle to the plane of rota-
tion attempts to bend the blade back
against the tower, while the force ÒFdÓ
points in the direction of rotation and
provides the driving torque. We may
notice two very important differences
between the forces on the blade in
these two different situations and forces
on the cyclist in the two corresponding
situations. One difference is that the
forces on the blade become very large
during rotation. If vector arrows illu-
strating the forces in the diagrams were
drawn in a scale that was indicative of the
sizes of the different forces, then these
vector arrows of a wind turbine in opera-
tion would have been 20 times the size of
the vector arrows of the same wind
turbine at rest. This large difference is
due to the resulting wind speed of 51 m/s
striking a blade during operation, many
times the wind speed of 10 m/s when the
wind turbine is at rest. Just like the
cyclist, the blade encounters head wind
resulting from its own movement,
however head wind is of far greater
importance on a wind turbine blade than
for a cyclist in motion.
The other important difference
between a wind turbine blade and a
cyclist is that the force on the blade is
almost at a right angle to the resulting
wind striking the profile. This force is
known as the lift and also produces a
small resistance or drag. The direction of
this lift force is of great importance. A
cyclist only feels the wind resistance as a
burden, requiring him to push down extra
hard on the pedals. However with a wind
turbine blade this extra wind resistance
will act as a kind of power booster, at
least in the normal blade rotational speed
range. The reason for this difference is
due to the blades streamlined profile,
which behaves aerodynamically com-
pletely differently as compared to the
irregular shaped profile of a man on a
bicycle. The wind turbine blade experi-
ences both lift and drag, while a cyclist
only experiences drag.
LIFT
Lift is primary due to the physical pheno-
mena known as BernoulliÕs Law. This
physical law states that when the speed of
an air flow over a surface is increased the
pressure will then drop. This law is
counter to what most people experience
from walking or cycling in a head wind,
where normally one feels that the
pressure increases when the wind also
increases. This is also true when one sees
Blow!
An experiment with BernoulliÕs Law
an air flow blowing directly against a
surface, but it is not the case when air is
flowing over a surface.
One can easily convince oneself that this
is so by making a small experiment. Take
two small pieces of paper and bend them
slightly in the middle. Then hold them as
shown in the diagram and blow in
between them. The speed of the air is
higher in between these two pieces of
paper than outside (where of course the
air speed is about zero), so therefore the
pressure inside is lower and according to
BernoulliÕs Law the papers will be
sucked in towards each other. One would
expect that they would be blown away
from each other, but in reality the
opposite occurs. This is an interesting
little experiment, that clearly demonstra-
tes a physical phenomenon that has a
completely different result than what one
would expect. Just try for yourself and
see.
The aerodynamic profile is formed
with a rear side, that is much more curved
than the front side facing the wind.
Two portions of air molecules side by
side in the air flow moving towards the
profile at point A will separate and pass
around the profile and will once again be
side by side at point B after passing the
profileÕs trailing edge. As the rear side is
more curved than the front side on a wind
turbine blade, this means that the air
flowing over the rear side has to travel a
longer distance from point A to B than
the air flowing over the front side.
Therefore this air flow over the rear side
must have a higher velocity if these two
different portions of air shall be reunited
at point B. Greater velocity produces a
pressure drop on the rear side of the
blade, and it is this pressure drop that
produces the lift. The highest speed is
obtained at the rounded front edge of the
B
A
Air flow around an aerodynamic profile
blade. The blade is almost sucked
forward by the pressure drop resulting
from this greater front edge speed.
There is also a contribution resulting
from a small over-pressure on the front
side of the blade.
Compared to an idling blade the
aerodynamic forces on the blade under
operational conditions are very large.
Most wind turbine owners have surely
noticed these forces during a start-up in
good wind conditions. The wind turbine
will start to rotate very slowly at first,
but as it gathers speed it begins to
accelerate faster and faster. The change
from slow to fast acceleration is a sign
that the bladeÕs aerodynamic shape
comes into play, and that the lift greatly
increases when the blade meets the head
wind of its own movement. The fast
acceleration, near the wind turbineÕs
operational rotational speed places great
demands on the electrical cut-in system
that must Òcapture and engage Ò the wind
turbine without releasing excessive peak
electrical loads to the grid.
THE CHANGE OF FORCES
ALONG THE BLADE
The drawings previously studied, mainly
illustrate the air flow situation near the
8
F
F Fa
Plane of rotation
v v
A B
Air flow around a blade profile near the blade root
blade tip. In principle these same
conditions apply all over the blade,
however the size of the forces and their
direction change according to their
distance to the tip. If we once again look
at a 450 kW blade in a wind speed of
10 m/s, but this time study the situation
near the blade root, we will obtain
slightly different results as shown in the
drawing above.
In the stationary situation (A) in the
left hand drawing, wind pressure is still
80 N/m2 . The force ÒFÓ becomes slightly
larger than the force at the tip, as the
blade is wider at the root. The pressure is
once again roughly at a right angle to the
flat side of the blade profile, and as the
blade is more twisted at the root, more
of the force will be directed in the direc-
tion of rotation, than was the case at the
tip.
On the other hand the force at the root
has not so great a torque-arm effect in
relation to the rotor axis and therefore it
will contribute about the same force to
the starting torque as the force at the tip.
During the operational situation
as shown in the center drawing (B),
the wind approaching the profile is once
again the sum of the free wind ÒvÓ of
10 m/s and the head wind ÒuÓ from the
blade rotational movement through the
air. The head wind near the blade root of
a 450 kW wind turbine is about 15 m/s
and this produces a resulting wind ÒwÓ
over the profile of 19 m/s. This resulting
wind will act on the blade section with a
force of about 500 N/m2.
In the drawing on the right (C) force
is broken down into wind pressure
against the tower ÒFaÓ, and the blade
driving force ÒFdÓ in the direction of
rotation.
In comparison with the blade tip the
root section produces less aerodynamic
Plane of rotation
Fd
u wide profile) and the desire for good
w aerodynamic properties (the thin profile)
C
forces during operation, however more of
these forces are aligned in the correct
direction, that is, in the direction of
rotation. The change of the size and
direction of these forces from the tip in
towards the root, determine the form and
shape of the blade.
Head wind is not so strong at the
blade root, so therefore the pressure is
likewise not so high and the blade must
be made wider in order that the forces
should be large enough. The resulting
wind has a greater angle in relation to the
plane of rotation at the root, so the blade
must likewise have a greater angle of
twist at the root.
It is important that the sections of
the blade near the hub are able to resist
forces and stresses from the rest of
the blade. Therefore the root profile is
both thick and wide, partly because the
thick broad profile gives a strong and
rigid blade and partly because greater
width, as previously mentioned, is
necessary on account of the resulting
lower wind speed across the blade. On
the other hand, the aerodynamic behavior
of a thick profile is not so effective.
Chord
The angles of the profile
Further out along the blade, the profile
must be made thinner in order to produce
acceptable aerodynamic properties, and
therefore the shape of the profile at any
given place on the blade is a compromise
between the desire for strength (the thick
with the need to avoid high aerodynamic
stresses (the narrow profile).
As previously mentioned, the blade
is twisted so that it may follow the
change in direction of the resulting wind.
The angle between the plane of
rotation and the profile chord, an
imaginary line drawn between the
leading edge and the trailing edge,
is called the setting angle, sometimes
referred to as ÒPitchÓ.
WHAT HAPPENS WHEN
THE WIND SPEED CHANGES?
The description so far was made with
reference to a couple of examples where
wind speed was at a constant 10 m/s.
We will now examine what happens
during alterations in the wind speed.
In order to understand blade behavior
at different wind speeds, it is necessary
to understand a little about how lift and
drag change with a different angle of
attack. This is the angle between the
resulting wind ÒwÓ and the profile chord.
In the drawing below the angle of
attack is called ÒaÓ and the setting
angle is called ÒbÓ.
The setting angle has a fixed value at
any one given place on the blade,
but the angle of attack will grow as the
wind speed increases.
Plane of rotation
a
b
w
9
Lift
Coefficients of Lift and Drag (CL & CD)
Angle of attack ÓaÓ
Relationship between lift and drag coefficients and the angle of attack
The aerodynamic properties of the
profile will change when the angle of
attack ÒaÓ changes. These changes of lift
and drag with increasing angles of attack,
are illustrated in the diagram above used
to calculate the strength of these two for-
ces, the lift coefficient ÒCLÓ and the drag
coefficient ÒCDÓ. Lift will always be at a
right angle to the resulting wind, while
drag will always follow in the direction
of the resulting wind.
We will not enter into the formulas
necessary to calculate these forces, it is
enough to know that there is a direct con-
nection between the size of ÒCLÓ and the
amount of lift.
Both lift and drag abruptly change
when the angle of attack exceeds 15-20
degrees. One can say that the profile
stalls. After this stalling point is reached,
lift falls and drag increases. The angle of
attack changes when the wind speed
changes.
To further study these changes, we
can draw diagrams, shown to the right,
illustrating three different wind speeds
ÒvÓ (5, 15 and 25 m/s) from our previous
cross section, this time near the blade tip
of a 450 kW wind turbine. This situation
is rather convenient as the setting angle
ÒbÓ near the wing tip is normally
0 degrees.
The head wind from the movement
ÒuÓ is always the same, as the wind
turbine has a constant rotational speed
drag is 0.07. Lift is now 20 times drag.
¥ At a wind speed of 25 m/s (C), the
profile is now deeply stalled, the angle of
Drag
attack is 27 degrees, the lift component is
1.0 and the component of lift is 0.35. Lift
is now 3 times greater than drag. We can
therefore note the following:
¥ During the change of wind speed from
5 to 15 m/s there is a significant increase
in lift, and this increase is directed in the
direction of rotation. Therefore power
output of the wind turbine is greatly
increased from 15 kW to 475 kW.
¥ During the change of wind speed from
15 to 25 m/s, there is a drop in lift
accompanied by an increase in drag.
This lift is even more directed in the
direction of rotation, but it is opposed by
drag and therefore output will fall slightly
to 425 kW.
controlled by the grid connected
generator (in these situations we do not
consider the small generator used on F
certain small wind turbines). The free air
flow ÒvÓ has three different values and
this gives three different values of the Plane of rotation
resulting wind ÒwÓ across the profile. A
u
The size of ÒwÓ does not change very
w
much, from 50 m/s at a wind speed of v (5 m/s)
5 m/s to 52 m/s in a 25 m/s wind. The
reason for this relatively minor change is
due to the dominating effect of the head
wind.
F
However, the angle of attack ÒaÓ
between the resulting wind and the chord
of the blade changes from 6 degrees at
a wind speed of 5 m/s to 16 degrees at B
Plane of rotation
15 m/s to 27 degrees at 25 m/s. These u
changes are of great importance for
determining the strength of the aerody- w
namic forces. v (15 m/s)
Studying the diagram showing the lift
coefficient ÒCLÓ and the drag coefficient
ÒCDÓ we may note the following:
¥ At a wind speed of 5 m/s (A), the F
angle of attack is 6 degrees. The lift
coefficient is 0.9 and the coefficient of
drag is 0.01. Lift is therefore 90 times Plane of rotation
C
greater than drag, and the resultant force u
ÒFÓ points almost vertically at a right
angle to the mean relative wind ÒwÓ.
¥ At a wind speed of 15 m/s (B), the w
profile is almost about to stall. The angle v (25 m/s)
of attack is 16 degrees. The lift
Situations at three different wind speeds
coefficient is 1.4 and the coefficient of
10
Seperation of the air flow at the profile trailing edge
THE STALL PHENOMENA
The diagrams showing the components of
lift and drag illustrate the result of stall.
Lift diminishes and drag increases at
angles of attack over 15 degrees. The
diagrams however do not illustrate the
reasons for this stall phenomena.
A stall is understood as a situation
during which an angle of attack becomes
so large that the air flow no can longer
flow smoothly, or laminar, across the
profile. Air looses contact with the rear
side of the blade, and strong turbulence
occurs. This separation of air masses
normally commences progressively from
the trailing edge, so the profile gradually
becomes semi-stalled at a certain angle of
attack, but a full stall is first achieved at
a somewhat higher angle. From the
diagram showing the lift and drag
components, one can estimate that the
separation at the trailing edge starts at
about 12 degrees, where the curve
illustrating lift starts to fall. The profile
is fully stalled, and the air flow is
separated all over the rear side of the
blade at about 20 degrees. These figures
can greatly vary from profile to profile
and also between different thicknesses of
the same profile.
When the stall phenomena is used to
restrict power output, as in all Bonus
wind turbines, it is important that blades
are trimmed correctly. With the steep lift
curve, the angle of attack cannot be
altered very much, before maximum
output also changes, therefore it is
essential that the angle of the blade is
set at the correct value.
One cannot alter the different angles
on the blade itself, once the form, shape
and blade molding has been decided upon
and fabricated. So we normally talk
about calibrating the tip angle. Not
because the blade tip has any special
a small section of the blade. This altered
section will then produce a stall over the
greater part of the blade. For example,
the Bonus 450 kW Mk III turbine, is
usually equipped with a 0.5 meter stall
strib, which controls the stall process all
over the 17 meter long blade.
Stall strip
Interference in the stall process (stall strip)
SUMMARY
The main points as described in this
article can be shortly stated in the
following:
magical properties, but we can place a
template at the tip, which allows us to ¥ The air flow around a wind turbine
make measurements using a theodolite. blade is completely dominated by the
Adjusting of the tip angle can therefore head wind from the rotational movement
be understood as an example of how the of the blade through the air.
angle of the total blade is adjusted.
Of importance for power output ¥ The blade aerodynamic profile
limitation is also the fact that in practice produces lift because of its streamlined
lift and drag normally behave exactly as shape. The rear side is more curved than
would be expected from the theoretical the front side.
calculations. However this is not always
the case. Separation can often occur ¥ The lift effect on the blade aerodyna-
before expected, for instance due to dirt mic profile causes the forces of the air to
on the leading edges, or it can be delayed point in the correct direction.
if the air flow over the profile for some
reason or other, is smoother than usual. ¥ The blade width, thickness, and twist is
When separation occurs before expected, a compromise between the need for stre-
the maximum obtainable lift is not as amlining and the need for strength.
high as otherwise expected and therefore
maximum output is lower. On the other ¥ At constant shaft speed, in step with the
hand, delayed separation can cause con- grid, the angle of attack increases with
tinuous excessive power production increasing wind speed. The blade stalls
output. when the angle of attack exceeds
Accordingly profile types chosen for 15 degrees. In a stall condition the air
our blades have stable stall charac- can no longer flow smoothly or laminar
teristics with little tendency to unforeseen over the rear side of the blade, lift
changes. From time to time, however, therefore falls and drag increases.
it is sometimes necessary to actively alter
the stall process. This is normally done
by alteration to the leading edge, so that
a small well-defined extra turbulence
across the profile is induced. This extra
turbulence gives a smoother stall process.
Turbulence can be created by an area
of rougher blade surface, or a triangular
strip, fixed on the leading edge. This stall
strip acts as a trigger for the stall so that
separation occurs simultaneously all over
the rear side.
On a wind turbine blade, different air
flows over the different profile shapes,
interact with each other out along the
blade and therefore, as a rule, it is only
necessary to alter the leading edge on
11
THE TRANSMISSION SYSTEM
Main bearing
Hub
The link between the wind turbine blades and the generator
Just how much of a wind turbine that
belongs to the transmission system is a
matter of definition. In this chapter we
will include the components that
connect the wind turbine rotor to the
generator.
THE HUB
The blades on all Bonus wind turbines
are bolted to the hub. Older Bonus wind
turbines (up to and including the 95 kW
models) with Aerostar blades, have a
flange joint, where the glass fiber
is molded out in a ring with steel bushes
for the bolts. The newer wind turbines
(from the 150 kW models) have threaded
bushes glued into the blade root itself.
In both cases bolts from the blade
pass through a flange on the cast hub.
The flange bolt-holes are elongated,
enabling the blade tip angle to be
adjusted.
The hub is cast in a special type
of strong iron alloy, called ÒSG cast
ironÓ. Because of the complicated hub
shape which is difficult to make in any
other way, it is convenient to use cast
iron. In addition the hub must be highly
resistant to metal fatigue, and this
is difficult to achieve in a welded
construction.
Gear
Main shaft
In contrast to cast iron of the SG type,
normal cast iron has the disadvantage of
being rather fragile and often can
fracture under blows. This unfortunate
quality is due to the high carbon content
of cast iron. High carbon content enables
the cast iron to melt easily and thus
easily flow out into the casting form.
When cast iron solidifies, carbon exists as
graphite flakes suspended in the pure
iron. These flakes form weak zones in the
material, easily prone to zig-zag fissures
from flake to flake. These weak zones are
only important, if forces attempt to pull
Wind turbine hub
Coupling
the material apart. Graphite has great
compressibility strength, and is therefore
not easily compressed. Normal cast iron
has the same compressibility strength as
steel, but its tension resistance level is
only 10% of steel tension resistance.
For many uses these strength qualities
are more than sufficient, however in
constructions subject to heavy usage,
properties such as low tension resistance
and weakness under blows are not
desirable. For this reason special SG cast
iron with tension resistance equal to that
of steel has been developed during the
past 50 years.
In producing SG cast iron several
special materials, mainly silicium, are
added during casting. After casting has
taken place, it is further heat treated for
about 24 hours, thereby changing the free
carbon from their usual flakes into small
round balls. The name SG cast iron is
also short for Spherical Graphite cast iron
(latin: Sphere = ball).
This round ball shape binds the
necessary carbon in a more compact
form. The graphite is not a hindrance for
the binding structure in the metal itself,
and there is likewise a better structure
between the crystals of iron. Thereby
achieving the higher strength qualities
12
necessary for a wind turbine hub.
On account of the extra heat treatment,
SG cast iron is somewhat more expensive
than normal cast iron.
MAIN SHAFT
The main shaft of a wind turbine is
usually forged from hardened and
tempered steel. Hardening and tempering
is a result of forging the axle after it
has been heated until it is white-hot
at about 1000 degrees centigrade. By
hammering or rolling the blank is formed
with an integral flange, to which the hub
is later bolted.
The shaft is reheated a final time to a
glowing red, following the forging
process, and then plunged into a basin of
oil or water. This treatment gives a very
hard, but at the same time rather brittle
surface. Therefore the axle is once again
reheated to about 500 degrees centigrade,
tempering the metal and thereby enabling
the metal to regain some of its former
strength.
Spherical roller bearing ¥ (Niemann)
MAIN BEARINGS
All modern wind turbines, including the
Bonus models, have spherical rolller
bearings as main bearings. The term
spherical means that the inside of the
bearingÕs outer ring is shaped like a cross
section of a ball. This has the advantage
of allowing the bearingÕs inner and outer
ring to be slightly slanted and out-of-
track in relation to each other without
damaging the bearing while running.
The maximum allowable oblique angle is
normally 1/2 degree, not so large, but
large enough to ensure that any possible
small errors in alignment between the
wind turbine shaft and the bearing
housing will not give excessive edge
loads, resulting in possible damage to the fits over the rear end of the main shaft.
bearing. Torque between the two components is
The spherical bearing has two sets transferred by friction between the two.
of rollers, allowing both absorption A clamping unit, normally composed
of radial loads (across the shaft) from of an inner ring and two outer rings with
the weight of the rotor, shaft, etc. and conical facings, is placed on the outside
the large axial forces (along the shaft) of the gearÕs hollow shaft. When the main
resulting from the wind pressure on shaft is placed inside the hollow shaft
the rotor. during the assembly of the wind turbine,
The main bearings are mounted in the the conical facings of the clamping unit
bearing housings bolted to the main are loosely positioned on the hollow
frame. The quantity of bearings and shaft. Following control of the correct
bearing seats vary among the different alignment of the gear and the main shaft,
types of wind turbines: Ò Small Ó wind the rings are tightened by the means of a
turbines up to and including 150 kW have large number of bolts. The outer rings are
two bearings, each with its own flanged thereby pressed together, while the inner
bearing housing. The 250/300 kW wind ring, positioned on the hollow shaft is
turbines have only one main bearing, pressed inwards under the tightening of
with the gearbox functioning as a second the bolts. The inner ring now presses so
main bearing. The 450 kW, 500 kW and hard against the hollow shaft that the
600 kW wind turbine models have two inner part of the hollow shaft is in turn
main bearings, using the hub as a pressed hard against the main shaft. It is
housing. Each bearing arrangement has because of this pressure that the torque is
advantages and disadvantages, and the
evaluation of these properties have
provides each individual type with its
own setup.
The main bearings are always
lubricated by greasing, no matter which
bearing arrangement is selected. Special
grease having viscose properties even in
hard frost is used.
Sealing of the bearing housing is
insured by the use of a labyrinth packing.
No rubber sealing is used, the labyrinth
with its long and narrow passageway
prevents grease from escaping. Water and
dirt are prevented from entering from the
outside by the long passageways filled
with grease, which is constantly and
Outer rings
slowly trying to escape from the bearing.
This may appear to be a rather primitive
arrangement, but labyrinth packing is a
¥ Inner ring
much used method where there is great Main shaft
risk of pollution by water and dirt. It is
more expensive to use than a rubber sea- ¥
ling, because the labyrinth is complicated
to fabricate on machine tools, however
the seal is not subject to wear, and under
normal conditions it is a safe method to
keep out the pollutants that otherwise in a
¥ Hollow shaft
short time could ruin roller bearings.
THE CLAMPING UNIT
By the means of a clamping unit the main
shaft of the wind turbine is coupled to the
Clamping unit ¥ (TAS ShŠfer)
gearbox. The gear has a hollow shaft that
13
transferred from the main shaft to the
wind turbine gear hollow shaft. One
might also say that the hollow shaft is
shrink-fitted on the main shaft as a result
of pressure from the clamping unit.
Transferred torque is dependent upon
friction between the main shaft and
the hollow shaft. Therefore it is vital that
the components are carefully cleaned
and completely dry, before they are
assembled. If they are at all greasy, they
could slip in relation to each other during
high loads, for example during the cut-in
process in strong wind conditions.
Many know of the parallel key
method, often used in assembling a shaft
to a hub. The main shaftÕs torque is
transferred by forces across the parallel
key (a parallel key is often called a
wedge, even though it is not wedge
shaped). This assembly method is not
often used with a large shaft, there being
too great a risk that in time the different
parts could loosen, unless they fit uncom-
monly well together. If the parallel key
junction assembly method is used for
large shafts, parts must fit so well
together, that in practice one is unable to
dismantle them in the field, should it be
necessary during possible replacement in
case of damage or repair.
THE GEARBOX
One of the most important main com-
ponents in the wind turbine is the
gearbox. Placed between the main shaft
and the generator, its task is to increase
the slow rotational speed of the rotor
blades to the generator rotation speed of
1000 or 1500 revolutions per minute
(rpm).
Without much previous experience with
wind turbines, one might think that the
gearbox could be used to change speed,
just like a normal car gearbox. However
this is not the case with a gearbox in a
wind turbine.
In this case the gearbox has always a
constant and a speed increasing ratio,
so that if a wind turbine has different
operational speeds, it is because it has
two different sized generators, each with
its own different speed of rotation (or one
generator with two different stator
windings).
As an example of a gearbox
construction, we can study a Flender
1 Hollow shaft
2 Intermediate shaft
3 High speed shaft
for the generator
Slow set
4 Large toothed wheel
5 Small toothed wheel
High speed set
6 Large toothed wheel
7 Small toothed wheel
Flender SZAK 1380 2-trins gear
SZAK 1380 gear for a 150 kW wind
turbine. This gear has two sets of toothed
gear wheels, a slow speed stage and a
high speed stage. In the slow speed stage
the large gear wheel is mounted directly
on the gearÕs hollow shaft, while the
smaller gear wheel is machined directly
on the intermediate shaft.
The difference in the size of the
wheels is 1:5. The intermediate shaft
therefore turns 5 times every time the
hollow shaft makes one complete
revolution. The large gear wheel in the
high speed gear stage is also mounted on
the intermediate shaft, while the small
gear wheel in the high speed gear stage is
machined on the generator shaft itself.
Here the difference in size is also about
1:5, so that the output shaft to the
generator shaft turns 5 times for every
one rotation of the intermediate shaft.
When the two ratios are combined,
the output shaft will turn 25 times for
every rotation of the hollow shaft and the
main shaft of the wind turbine combined
1 Ring wheel
2 Planet wheel
3 Sun wheel
4 Planet carrier
Planetgear ¥ /DIN 686/Niemann)
One can say that the gear has a gear ratio
of 1:25.
Normally the ratio in every set of gear
wheels is restricted to about less than 1:6.
The 150 kW wind turbine has a rotor
rotational speed of 40 rpm and with a
generator speed of about 1000 rpm, the
gearbox must have a total gear ratio of
40/1000 or 1:25. This is possible using a
two stage gearbox. A 300 kW wind
turbine has a rotor rotational speed of
31 rpm and a generator with a rotational
speed of 1500 rpm. It therefore requires a
gearbox with a gearbox ratio of 31/1500
or 1:48. This is not possible using a gear-
box with only two stages, so the 300 kW
wind turbine gearbox has an extra
intermediate shaft, giving in all a three
stage gearbox.
Wind turbines, from 450 kW and
larger, have an integrated gearbox with a
planet gear and two normal stages. The
planet gear is a special version of the
toothed gear. This type of gear is of great
delight to gearbox technicians, as it can
14
be combined in countless different com-
plicated variations, each one carefully
calculated with its own special inner
logic. The form of planet gear used on
wind turbines is however always of the
same basic design: An interior toothed
gear wheel (ring wheel), three smaller
toothed gear wheels (planet wheels)
carried on a common carrier arm (the
planet carrier ) and finally a centrally
placed toothed gear wheel (the sun gear
wheel). It is this construction, with three
smaller gear wheels orbiting a centrally
placed common gear wheel that has given
this type of gear its name of planet gear-
box.
The ring wheel itself is stationary,
while the planet carrier is mounted on the
hollow shaft. When the planet carrier
rotates with the same rotational speed as
the rotor blades, the three planet wheels
turn around inside the inner circum-
ference of the ring wheel and thereby also
greatly increase the rotational speed of
the centrally placed sun gear wheel. One
can usually obtain a gear ratio of up to
about 1:5. The sun gear wheel is fixed to
an shaft driving the two normal gear
stages placed at the rear end of the
gearbox.
The fact that there are always three
gear wheels supporting each other and
that all gear wheels are engaged at the
same time, is one of the advantages of the
planet gear. This means that it is possible
to construct rather compact planet gear-
boxes, because the larger ring wheel does
not need to be as large as a gear wheel in
a traditional type of gearbox. In principle
it only needs to be about a 1/3 of the size.
However in reality it not quite so simple.
If a gear is needed to transfer heavy
loads, it is often somewhat cheaper to use
a planet gear.
However it is in the very nature of
things that trees do not grow up into
heaven, and also planet gears have their
own special disadvantages. The compact
construction, very practical for the design
and construction of the rest of the
machine, can be in itself a disadvantage.
The compact construction makes it
difficult to effectively dissipate excess
heat to the surroundings. A gear is not
100% effective, and as a rule of thumb it
is estimated that roughly 1% of the
power is lost at each stage. A 600 kW
gearbox running at full capacity, must
therefore dispose of about 18 kW of
waste heat. This is equivalent to nine
normal household hot air blower-heaters
operating at full blast. This waste heat
should preferably be radiated by surface
cooling and of course the less gearbox
surface area, the higher the temperature
must be inside the gearbox to transfer the
necessary, unavoidable excess waste
heat.
Another disadvantage of the planet
gear is that they normally cannot be
constructed with bevelled machined
teeth. Bevelled teeth are always used in
normal gearboxes in order to reduce the
noise level. When the teeth are set at an
angle, the next tooth will start to engage
and take up the load before the previous
tooth has slipped contact. This results in a
quieter, more harmonious operation. For
interior gear wheels bevelled teeth can
only be machined using special machine
tools that up until now have solely been
used for the machining of very large
turbine gears for use in ships. Therefore
planet gears have always straight
machined teeth, unfortunately however,
resulting in a higher noise level. By
combining a planet gear stage and two
normal gear stages, one obtains an
acceptable compromise of the advantages
and disadvantages with the two different
types of gear.
No matter what type of gear is used,
the shape of the teeth in the different
gear stages are adapted to the special
conditions for wind turbine operation,
especially those that are related to the
noise level. Teeth as a rule are case-har-
dened and polished. Case-hardening is a
method of giving surface strength to a
specific material. During this process, the
inner material maintains its previous
strength, which can often be lost in
normal steel hardening processes.
Hardening can only take place under
conditions where there is a carbon content
in the steel. The gear wheels are made of a
special low carbon chrome-nickel steel.
The teeth are first machined, and
following the machining process, the gear
wheels are packed into large boxes full of
bone flour or some other form of high
carbon-content powder. The boxes are
placed in an oven and heated for about 24
hours to a red glowing temperature.
During this baking process some of the
free carbon will be transferred from the
surrounding carbon-rich powder in the
boxes to the gear wheel teeth surfaces.
This is described as the method of harde-
ning the teeth in boxes or cases, and
therefore from this process comes the
descriptive name of case-hardening.
The increased carbon content of the
teeth surface allows the top edges of the
gear wheel teeth to become harder, so
following case hardening, the gear wheel
is lifted out, still red hot, and lowered into
an oil bath. This completes the process of
hardening, and the gear wheel now has a
hardened surface, while the inner
material still has ductile and not hardened
properties. The hardening process
slightly deforms the material, so it is
necessary to finish the process by
grinding.
THE COUPLING
Coupling¥ (Flender BIPEX)
The coupling is placed between the gear-
box and the generator. Once again it is
not possible to consider the coupling as
the same as a clutch in a normal car. One
cannot engage or disengage the transmis-
sion between the gearbox and the genera-
tor by pressing a pedal, or in some other
such way. The transmission is a
permanent union, and the expression
ÒcouplingÓ should be understood as a
junction made by a separate machine
component.
The coupling is always a ÒflexibleÓ
unit, made from built-in pieces of rubber,
normally allowing variations of a few
millimeters only. This flexibility allows
for some slight differences in alignment
between the generator and the gearbox.
This can be of importance under
assembly and also during running opera-
tion, when both gearbox and generator
can have tendencies for slight movement
in relation to each other.
15
The generator is the unit of the wind
turbine that transforms mechanical
energy into electrical energy. The blades
transfer the kinetic energy from the
wind into rotational energy in the trans-
mission system, and the generator is the
next step in the supply of energy from
the wind turbine to the electrical grid.
In order to understand how a generator
works, it is necessary to first of all under-
stand the deeper principles in the
electrical system to which the generator
is connected. Therefore we will first
discuss the electrical systems based on
Direct Current (DC) and those based on
Alternating Current (AC).
DIRECT CURRENT (DC)
During the first use of electricity for
lighting and power in the previous
century, systems based on direct current
were used. In DC systems the voltage is
at a constant level. This could be
1.5 Volts (V) as in a modern alarm clock,
12 V as in a car or 110 V as in the first
proper electrical grid.
DC has the advantage that batteries
can be connected, enabling a continual
supply of electrical power even if the
generator at the power station ceases
operation and shuts down. Therefore the
first power stations had large store
rooms full of long rows of batteries.
Such systems were well adapted to the
use of wind turbines as a main power
source, for with such large stocks of
batteries, power could still be supplied
even in calm periods.
The battery store room of a wind power plant at the
beginning of the 1900«s ¥ (H.C.Hansen: Poul la Cour)
THE GENERATOR
The wind turbine electrical system
In spite of the advantages of battery
energy storage, DC is no longer used in
larger grid electrical supply systems. This
is due to some important disadvantages
of direct current, while on the other hand
the competing electrical system alterna-
ting current offers important advantages.
One of the big disadvantages of DC
is the strong electrical arc produced,
when the electrical current connection
from supply to user is cut at higher
voltages. For example, in larger instal-
lations with connections to electrical
motors DC switches are both large and
complicated. Therefore in practice DC
systems can be rather inconvenient.
Voltage (V)
DC-current
Time
DC-system
Another ÒdisadvantageÓ is that the
advantages of battery energy storage
do not in reality exist with the
electrical grid systems in common use
today. This is because our present-day
energy consumption greatly exceeds
the capacity of this technology.
A typical Danish family has an energy
consumption of about 5.000 kWh per
year, or about 13.7 kWh per day. A
normal car battery has a capacity of about
60 Ah (Ampere-hours). This means that a
car battery can supply an electrical cur-
rent equal to 1 Ampere for about 60 hours
at a battery voltage of 12 Volts. The
energy in a fully charged battery can be
calculated by the use of a simple formula:
E = 60 Ah x 12 V = 0.72 kWh
Therefore less than 1 kWh is stored in a
fully charged car battery. A typical
Danish family with a daily requirement
of 13,7 kWh kWh per day will thus need
19 fully charged batteries just to cover the
power consumption of a single day
without a supply from the power station
grid network.
Another example: In a good high
wind period a 600 kW wind turbine can
typically produce about 10.000 kWh per
day. This is enough to charge about
14.000 car batteries per day, were it is not
possible to supply this energy production
for the direct consumption or use by the
owner, or for supply to other consumers
connected to the grid.
In connection with such large quanti-
ties of energy, storage in batteries is not
feasible, and the storage possibilities
offered by the use of DC systems are not
really practically relevant.
ALTERNATING CURRENT (AC)
The voltage of the current constantly
varies around zero in an AC electrical
system. The maximum voltage must be
somewhat higher than a DC system in
order to give the same power. One can
speak of an effective medium voltage as a
kind of average of the voltage.
AC measuring instruments usually
show the effective middle voltage value
and not the maximum voltage.
A lamp connected to an alternating
electrical current will blink, as the
voltage constantly varies. The frequency
of the voltage variation or cycles in
Denmark, and most other countries is 50
Hz (50 cycles per second). Such rapid
cycles make the blinking of the lamp of
no real importance. The glowing wire in
Voltage (V)
Max. voltage (V)
Eff. medium voltage
Time
AC-current
AC-system
16
a normal electric bulb does not have time
to become cold in the short period
between cycles, and therefore does not in
practice blink. In comparison light emit-
ting from a neon tube is completely shut
off each time the voltage is at zero. The
eye however cannot distinguish variati-
ons in light intensity that occur faster
than 15 times a second, so therefore we
see light from a neon tube also as con-
stant.
The main advantage of alternating
current over direct current is that the
voltage can be altered using transfor-
mers. This is not the place to describe in
detail the functioning of a transformer,
but in principal it is possible to alter from
one voltage to another voltage almost
without loss of energy.
Most know the small transformers
used as power supply to radios, mobile
telephones, etc. A small box is plugged
into a 220 volt outlet connected to the
grid and 9 volts comes out at the other
end (normally also rectified to direct
current, but that is another story). For the
grid as a whole, it is the transformation to
a higher voltage that is of importance.
The advantage of high voltage is that
energy losses in power transmission
lines, are greatly reduced by using
increased voltages. In order to under-
stand this, one must know a couple of the
fundamental formulas in electrical
engineering. As an example consider the
case of a typical 220 volt electrical tool,
a 2.200 Watt (W) grinder.
The current one obtains at specific
power and voltage ratings may be calcu-
lated with the formula:
I = P/U
Where ÓIÓ is the current, ÓPÓ is the
power and ÓUÓ is the voltage. In the
example of the grinder, with power P =
2.200 W and voltage U = 220 V We
obtain the current of 2.200 / 220 = 10 A.
The power loss from the wires may be
calculated with the formula:
T = R x I2
Where ÓTÓ is the power loss and ÓRÓ is
the resistance of the wire. A normal
household electric wire with a cross
section of 1.5 mm2 has a resistance of
0.02 Ohm per meter. A 10 meter long
wire will have a resistance of 0.2 Ohm
and the power loss in the wire will
therefore be T = 0.2 x 10 2 = 20 W.
This is not so much, only about 1% of the
grinderÕs usable power.
The power loss is however quite
significant, when one considers the
distance from the user to the power
station. With a typical distance of about
20 km , the resistance in a 1.5 mm2 wire
will be about 400 Ohm, and the power
loss will therefore be T = 400 x 102 =
40,000 W or almost 20 times the power
of the grinder! Of course small 1.5 mm2
wires are not used as power supply cab-
les from the power station out to the
consumer, but even with large 50 mm2
cables, the power loss is still larger than
the rated power of the grinder.
It is in this situation that high voltage
transmission wires have their use.
If instead of 220 V the power station
sends an electrical current of 10.000 V
out in the electrical grid to the
consumer, the first formula for current
will give I = 2.200 /10.000 = 0.22 A,
and the other formula for power loss will
give T = 400 x 0.222 = 20 W still using
the same (unrealistic) wire dimension of
1.5 mm2. The use of high voltage power
lines has therefore reduced power loss
from an unacceptable level to that which
is more acceptable.
In practice current is transmitted from
power stations with a voltage of up to
400,000 V . This is then transformed to a
lower voltage in large centralized trans-
former stations, for example down to
10,000 V. Near the consumer the final
transformation down to 220 V is made.
For safety reasons high voltage is not
used near the consumer, as electrical
current becomes more dangerous, the
higher the voltage is increased. Likewise
the demands on the safety insulation of
electrical material also increases.
Voltage at any one given place on the
grid is therefore a compromise between
a desire on the one side for a minor
power loss (requiring high voltage), and
on the other hand the necessity of a low
or moderate risk of danger and at the
same time reasonably cheap electrical
installations (requiring lower voltage).
THREE PHASE
ALTERNATING CURRENT
Even though the cycles in the alternating
current are of no great importance for
lamps and other such things, it is
Voltage (Volt)
Time
Three phase AC (three super-imposed sinus curves)
impractical for certain other machines
that the current is always alternating
around zero. Therefore, years ago, it was
discovered that AC could be supplied
with three phases.
The principle of 3 phase electrical
power is that the generator at the power
station supplies 3 separate alternating
currents, whose only difference is that
they peak at three different times.
The knack with these three separate alter-
nating currents, or phases, is that it is
thereby possible to ensure that the sum
of the delivered power is always
constant, which is not possible with two
or four phases.
It is perhaps a little impractical with
three phase current, because it is necessa-
ry to run four different wires out to the
consumer, three different phase wires
and a neutral wire (zero). However for
electric motor use, the advantages of
three phase alternating current are many.
The voltage difference between two of
the phases is greater than that between
any one single phase and zero. Where the
voltage difference is 220 V between one
phase and zero, it is 380 V between two
phases.
This is often used in high energy
consumption equipment such as kitchen
ovens etc., which normally always are
connected to two phase power. In a
household installation usually only one
of the phases plus the neutral wire is led
to an ordinary socket. Normally the
installation has several groups, and one
phase will typically cover one part of the
house, and another phase will run to the
other rooms. Three phase sockets are
rather large and are often known as
power sockets, mainly because of their
use in electrical motor operation. For
ease in distinguishing between the diffe-
rent phases, in Denmark the three phases
have been named R, S, and T.
17
On the older Danish transmission lines
supported by wooden masts, phases were
placed in a certain specific order, reading
from the bottom up, according to the
Danish words for root (R), trunk (S) and
top (T).
INDUCTION
AND ELECTROMAGNETISM
Before finally describing the generator
itself, we must briefly explain a couple of
the basic principles of electromagnetism.
Many perhaps remember our school
days, when the physics teacher placed a
magnetic bar inside a coil of copper wire
connected to a measuring instrument.
S
Current
(I)
S Denmark by Johannes Juul, known for
Current
(I)
The principles of induction
If the magnet is stuck inside the coil, an
electric current is registered in the coil
circuit. If the magnet is withdrawn, a
current of the same strength is registered,
but in the opposite direction. The faster
the changes of the magnetic field in the
coil, the greater the current. The same
occurs if instead of the magnet being
stuck into the open coil it is merely
moved past one of the ends of the coil.
The effect is especially powerful if the
coil has a iron core.
One can say that alterations in the
magnetic field, induce a current in the
coil, and the phenomena is known as
induction.
In just the same way that a magnetic
field can bring about an electric current,
so can an electric current likewise cause a
magnetic field to be created. Electro-
magnetism was first demonstrated by the
Danish scientist H.C ¯rsted in his
famous experiment, where an electrical
current was able to turn a compass
needle. He had therefore demonstrated
the first electromagnet.
In practice a good electromagnet is
best made as a coil with an iron core, in
just the same way as the previously
mentioned form of coil that produces an
electric current when a magnet is moved
past at a close distance. Like a permanent
magnet an electromagnet has two poles, a
north pole and a south pole. The position
of these two poles depends on the directi-
on of the flow of electrical current.
THE WIND TURBINE GENERATOR
AS A MOTOR
The asynchronous generator we will
describe here is the most common type of
generator used in Danish wind turbines.
It is often referred to as the induction
generator, too. As far as we know the
asynchronous generator was first used in
the 200 kW Gedser wind turbine from
1
3 10
2
4 5
6
9
7
8
1. Generator shaft
2. Rolling bearings
3. Rotor
4. Rotor aluminium bar
5. Rotor aluminium ring
6. Stator
Components of an asynchronous motor
1957. Already some years prior to this
construction he erected a 13 kW
experimental wind turbine with an
asynchronous generator at Vester
Egesborg in the south of the large
Danish island of Zeeland.
The asynchronous generator is in
reality a type of motor that can also
operate as a generator, and we will first
consider this type as a motor. This is the
most common electric motor, sitting in
almost every washing machine, and
widely used as a motor unit in industry.
The motor consists of two main parts,
the stator and the rotor. The stator
contains a series of coils, the number of
which must be divisible by three. The
motor illustrated on this page has six
coils, placed in slots on the inside of the
stator, a cylinder assembled of thin iron
plates. The rotor sits on an axle placed
inside this stator. The rotor is also
assembled of thin iron plates. A row of
thick aluminum bars joined at each end
with an aluminum ring, fit in key ways on
the outer surface of the rotor. This rotor
construction looks a bit like a squirrel
cage, and accordingly the asynchronous
motor is also called a squirrel cage motor.
11
7. Coil
8. Stator plates
9. Coil heads
10. Ventilator
11. Connection box
18
Voltage
Voltage
Time
Voltage
Voltage
Time
4 situations of the rotation magnetic field
The six coils in the stator are connected
together, two by two to the three
different phases of the electrical grid.
This arrangement insures that there is a
rotating magnetic field inside the stator
itself. This is best illustrated by the abo-
ve diagram.
At a specific time Ò1Ó the current in
phase R is at its maximum, and this
produces a magnetic field with a strong
north pole at both the opposite coils
connected to the phase R. At phase S and
phase T the current is somewhat under
zero, and the two pairs of coils produce a
Time
Time
medium strength south pole, producing a
powerful south pole halfway between the
two coils.
At time Ò2Ó the current at phase S is
at a maximum, and the north pole is now
at the two opposing coils connected to
this phase. The current at phases R and T
is likewise reduced to under zero, and the
south pole is now between these two
coils.
At time Ò3Ó the current at phase T
now is at a maximum, and the north pole
is at the two coils connected to phase T.
The south pole has also turned, and is
now halfway between the coils connected
to phases R and S.
At time Ò4Ó the situation has now
returned to as it was at the start of the
electrical current rotation, with the north
poles at the end of the coils connected to
phase R.
In one complete cycle, from the
current peak to the next following peak,
the magnetic field has rotated through
half a circle. There are 50 cycles per
second, so the field turns at 25 times per
second, or 60 x 25 = 1.500 rpm
(revolutions per minute).
To understand how a generator
works, it is easiest to first consider two
different situations where a generator
operates as a motor, at 0 rpm. and at
1.500 rpm.
In the first case the rotor is stationary,
while the stator turns at 1.500 rpm. The
coils in the rotor experience rapid
variations of a powerful magnetic field.
A powerful current is thereby induced in
the short circuited rotor wire windings.
This induced current produces an intense
magnetic field around the rotor. The
north pole in this magnetic field is
attracted by the south pole in the statorÕs
turning magnetic field (and of course,
the other way round) and this will give
the rotor a torque in the same direction as
the moving magnetic field. Therefore the
rotor will start turning.
In the second situation, the rotor is
turning at the same speed as the stator
magnetic field of 1.500 rpm. This rotati-
onal figure is called the synchronous
rotational speed. When the stator mag-
netic field and the rotor are synchronized,
the rotor coils will not experience variati-
ons in the magnetic field, and therefore
current will not be induced in the short
circuited rotor windings. Without indu-
ced current in the rotor, there will be no
magnetic field in the rotor windings and
the torque will be zero.
On account of bearing friction the
motor must produce a little torque to
keep rotating, and therefore cannot run
at exactly the same speed as the rotating
magnetic field. As soon as the speed
slows down, there will be a difference
between the speed of the rotating mag-
netic field and the rotor. The rotor thus
again experiences a variation in the
magnetic field that induces a current in
19
the rotor windings. This current then pro-
duces a magnetic field in the rotor, and
the rotor can produce a torque.
During motor operation, the stator
experiences a constantly changing mag-
netic field, being dragged round by its
rotating magnetic field. During this
process, electrical current is induced in
the stator, which results in a power
consumption. In fact, the slower the rotor
turns in relation to the rotating magnetic
field of the stator, the stronger the indu-
ction in the stator, and therefore the gre-
ater the power consumption.
The fact that the rotor has no torque at
the precise synchronous rotational speed
and therefore will always run slightly
slower has given this motor type its
name, the asynchronous motor.
GENERATOR OPERATION
As we have previously mentioned, the
asynchronous motor can also run as a
generator. This simply happens when
you, instead of forcing the rotor to
turn at a rotational speed lower than
the synchronous speed, exceed this
synchronous speed by applying an out-
side energy source, such as a diesel motor
or a set of wind turbine rotor blades.
Once again, the greater the difference
between the rotating magnetic field of the
stator (which is always 1.500 rpm) and the
speed of the rotor, the greater the torque
produced by the rotor. When a working
as a generator, the rotating field however
acts as a brake in slowing the rotor. The
stator experiences a variable magnetic
field from the rotor that ÒdragsÓ its rota-
ting magnetic field and thereby induces an
electrical current in the stator. In compari-
son to motor operation the induced cur-
rents in the rotor and stator will flow in
the opposite direction, which means that
power will be sent to the grid. The faster
the rotor turns in relation to the rotating
magnetic field of the stator, the greater the
induction in the stator and the greater the
production of power.
In practice the difference between the
speed of rotational magnetic field of the
stator and the rotational speed of the rotor
is very little. A rotor will typically turn
about 1% faster at full power production.
If the synchronous rotational speed is
1.500 rpm then the rotor rotational speed
at full power will be 1.515 rpm.
The interesting torque curve of the
asynchronous electric motor, also operat-
ing as a generator, is shown below. At
speeds below the synchronous rotational
speed, the motor yields a positive torque.
Torque
Synchronous rpm
MOTOR 100%
rpm
GENERATOR 100%
Torque curve
Typically a maximum torque of about
2.5 times the torque of the nominal
power. If the rotational speed exceeds the
synchronous level, the torque becomes
negative, and the generator acts as a brake.
At the Bonus factory, we have a rather
interesting apparatus, that demonstrates
this shift between a motor and generator.
A small asynchronous motor is connected
to an electric meter. The motor has a gear-
box giving a shaft speed of 60 rpm.
A small crank handle is fixed to the
shaft. The motor starts when it is plugged
into a normal mains socket coming from
the electrical grid and consumes a small
amount of electrical energy due to friction
loss in the motor and gearbox.
If one attempts to resist the rotation of
the shaft by holding back the crank, the
consumption of energy will increase. If the
crank however is used to increase the
speed of the motor, then the electric meter
will start to run backwards, showing that
current is flowing the other way. In this
way one can, by using human muscle
power, feed electrical power to the grid, in
just the same way that a wind turbine feeds
power to the grid. It is difficult to achieve
more than 1/20 kW so a work force of
twelve thousand employees is needed to
compete with one single 600 kW wind
turbine operating in a good wind. Visitors
to Bonus may try their hand at our
generator demonstration model.
CUT- IN
If a wind turbine is connected to the grid
during a period of no wind, the asyn-
chronous generator will operate as a motor
and drag the rotor blades round like a
large electric fan. The wind turbine
therefore is disconnected from the grid
during periods of calm.
The wind turbine is likewise discon-
nected during periods of low wind speeds,
allowing the blades to slowly rotate. The
control system of the wind turbine
however constantly monitors the rotatio-
nal speed, and after the blades reach a
certain pre-set level, the system permits a
gradual cut-in to the grid.
The cut-in to the grid is carried out by
the use of a kind of electronic contacts
called thyristors, allowing continuously
variable up and down regulation of the
electrical current. Such thyristors allow
smoother and gentler generator cut-in,
thus preventing sudden surges of current
causing possible grid damage. Likewise
this gentler switching procedure prevents
stress forces in the gearbox and in other
mechanical components. A direct cut-in,
using a much larger electrical switching
unit result in violent shock-effects, not
only to the grid but also to the whole trans-
mission system of the wind turbine itself.
Unfortunately, thyristors have the
disadvantage of an power loss of about
1-2%, so after the finish of the cut-in
phase, current is led past the thyristors
direct to the grid by the means of a
so-called Ò by-pass switch Ò.
CLOSING REMARKS
It has been necessary to make many
simplifications in the above description.
We have considered such important terms,
as self-induction, reactive current and
phase compensation to be too complicated
in a more general description such as this.
During the induction process, in reality it
is not an electric current that is created, but
an electromotive force giving rise to a
certain current dependent upon the
resistance.
We have used the rotational speed for
a 4-pole and 6 coil generator (3 x 2).
In the diagram showing the rotating field,
one can observe that there are 2 north
poles and 2 south poles, 4 in all. Other
generators may have 9 coils, which would
mean 3 north poles and 3 south poles.
Such a 6 pole generator has a synchronous
rota-tional speed of 1.000 rpm.
Bonus wind turbines up to and inclu-
ding the 150 kW models have 6 pole
generators, while the larger models have 4
pole generators.
20
CONTROL AND SAFETY SYSTEMS
Control and safety systems comprise
many different components. Common
for all of these is that combined toget-
her they are part of a more com-
prehensive system, insuring that the
wind turbine is operated satisfactory
and preventing possible dangerous
situations from arising.
Details in control and safety systems are
somewhat different according to different
types of wind turbines. We have in
previous articles described components
and their functions that roughly cover
most Bonus wind turbine models,
regardless of their age. However it is
necessary in this article to be much more
specific, so we choose to concentrate on
the Bonus 600 kW Mk IV.
PROBLEM DESCRIPTION
In constructing wind turbine control and
safety systems one is soon aware of a
couple of rather important problems.
These problems pose special demands on
the systems, because they have to
function in the complex environment of a
wind turbine.
The first problem is common to all
control and safety systems: A wind
turbine is without constant supervision,
apart from the supervision of the control
system itself. The periods between
normal qualified maintenance schedules
is about every 6 months, and in the
intervening 4,000 hours or so the control
system must function trouble-free,
whether the wind turbine is in an
operational condition or not.
In almost every other branch of indu-
stry there is a much higher degree of
supervision by trained and qualified staff.
On factory production lines, operatives
are normally always present during
production. For example, in power
stations the system is constantly super-
vised from a central control room. Should
a fault or breakdown occur, rapid inter-
vention is possible and, as a rule, one has
always some sort of good impression of
what has actually happened in any
unforeseen occurrence. However a wind
turbine must be able to look after itself
and in addition have the ability to register
faults and retrieve this stored information
concerning any special occurrence,
should things possibly not go exactly
quite as expected.
The high demands on reliability requ-
ire systems that are simple enough to be
robust, but at the same time give the pos-
sibility for necessary supervision. The
number of sensors and other active com-
ponents need to be limited as far as
possible, however the necessary com-
ponents must be of the highest possible
quality. The control system has to be
constructed so that there is a high degree
of internal control, and to a certain
degree the system must be able to carry
out its own fault finding.
The other problem most of all relates
to the safety systems. A wind turbine, if
not controlled, will spontaneously over-
speed during high wind periods. Without
prior control it can then be almost
impossible to bring to a stop.
Power (kW)
Wind speed (m/s)
Power curves at different rotational speeds (rpm)
During high wind, a wind turbine can
produce a much higher yield than its
rated power. The wind turbine blade
rotational speed is therefore restricted,
and the wind turbine maintained at the
rated power, by the grid-connected
generator.
If the grid connection is lost, by
reason of a power line failure or if the
generator for some other reason is
disconnected, while the wind turbine is in
operation, the wind turbine would
immediately start to rapidly accelerate.
The faster the speed, the more power it
is able to produce. The wind turbine is
in a run-away condition.
The following diagrams dramatically
illustrates run-away in high wind. The
first graph shows the power curve for the
600 kW wind turbine as a function of the
blade rotational speed. The bottom curve
illustrates the normal power curve con-
trolled by the generator, at a blade rotati-
onal speed of 27 rpm. The three other
curves show power production at 30 rpm,
40 rpm and 60 rpm.
60 rpm
40 rpm
30 rpm
27 rpm
21
Revolutions per minute (rpm)
Time after run-away (sec)
Rotational acceleration during run-away
At a wind speed of 20 m/s, a wind
turbine will normally produce slightly
under 600 kW. Allowed to accelerate a
mere 10% to a blade rotational speed of
30 rpm, it is then able to increase power
production to 1.000 kW. At a blade
rotational speed of 40 rpm the power
increases to 2.000 kW and 3.300 kW at
60 rpm. At a wind speed of 25 m/s, if
the blades were permitted to rotate at a
speed of 60 rpm, the power production
would be as high as 5.400 kW.
The second graph illustrates just how
rapidly the blade rotational speed
accelerates in a run-away situation. After
a mere 0.6 seconds the rotor speed
accelerates to 30 rpm, and after 2.5
seconds the blades achieve 40 rpm. As
noted above the power output at 40 rpm
is 2.000 kW, an output far above the
ability of the braking system to restrain.
So it is vital that the safety systems
must possess very rapid reactive response
in order to prevent such runaway.
95% of all deliberations behind
design of wind turbine safety systems
have to do with this one task of safely
regaining control of the wind turbine,
should the generator speed control
suddenly become non-operative during
high wind conditions, and thereafter
securely bring the wind turbine to a halt.
Basically there are two main methods by
which one prevents a run-away:
1. Either one can prevent that the
blades are actually able to
achieve this increased power
production under this con-
dition of rapidly accelerating
blade rotational speed.
2. Or by some other means one
can prevent the rotational speed
from rising to an unacceptably
dangerous level.
Here we have the principles for the use of
aerodynamic braking (1) and the mecha-
nical brake (2).
THE CONTROLLER
In one way or another the controller is
involved in almost all decision-making
processes in the safety systems in a wind
turbine. At the same time it must oversee
the normal operation of the wind turbine
and carry out measurements for statistical
use etc.
The controller is based on the use of a
micro computer, specially designed for
industrial use and therefore not directly
comparable with a normal PC. It has a
capacity roughly equivalent to that of a
80286 PC system processor. The control
program itself is not stored in a hard
disk, but is stored in a microchip called
an EPROM. The processor that does the
actual calculations is likewise a
microchip.
Most wind turbine owners are
familiar with the normal keyboard and
display unit used in wind turbine control.
The computer is placed in the control
cabinet together with a lot of other
types of electro-technical equipment,
contactors, switches, fuses, etc.
The many and varied demands of the
controller result in a complicated
construction with a large number of
different components. Naturally, the
more complicated a construction and the
larger the number of individual compo-
nents that are used in making a unit, the
greater the possibilities for errors.
This problem must be solved, when
developing a control system that should
be as fail-safe as possible.
To increase security measures against
the occurrence of internal errors, one can
attempt to construct a system with as few
components as possible. It is also
possible to build-in an internal automatic
Òself-supervisionÒ, allowing the control-
ler to check and control its own systems.
Finally, an alternative parallel back-up
system can be installed, having more or
less the same functions, but assembled
with different types of components. On
the 600 kW Mk. IV wind turbine, all
three principles are used in the control
and safety systems. These will be further
discussed one at a time in the following.
A series of sensors measure the con-
ditions in the wind turbine. These sensors
are limited to those that are strictly
necessary. This is the first example of the
targeted approach towards fail-safe
systems. One would otherwise perhaps
think, as we now have access to compu-
ters and other electronic devices with
almost unlimited memory capacity, that
it would merely be a matter of measuring
and registering as much as possible.
However this is not the case, as every
single recorded measurement introduces
a possibility for error, no matter how
high a quality of the installed sensors,
cables and computer. The choice of the
necessary sensors is therefore to a high
degree a study in the art of limitation.
 22
The controller measures the following
parameters as analogue signals (where
measurements give readings of varying
values ) :
¥ Voltage on all three phases
¥ Current on all three phases
¥ Frequency on one phase
¥ Temperature inside the nacelle
¥ Generator temperature
¥ Gear oil temperature
¥ Gear bearing temperature
¥ Wind speed
¥ The direction of yawing
¥ Low-speed shaft rotational speed
¥ High-speed shaft rotational speed
Other parameters that are obviously
interesting are not measured, electrical
power for example. The reason being that
these parameters can be calculated from
those that are in fact measured. Power
can thus be calculated from the measured
voltage and current
The controller also measures the
following parameters as digital signals
(where the measurements do not give
readings of varying values, but a mere an
on/off signal) :
¥ Wind direction
¥ Over-heating of the generator
¥ Hydraulic pressure level
¥ Correct valve function
¥ Vibration level
¥ Twisting of the power cable
¥ Emergency brake circuit
¥ Overheating of small electric
motors for the yawing,
hydraulic pumps, etc.
¥ Brake-caliper adjustment
¥ Centrifugal-release activation
Even though it is necessary to limit the
number of measurements, certain of
these are duplicated, for example at the
gearbox, the generator and the rotational
speed. In these cases we consider that the
increased safety provided, is more impor-
tant than the risk of possible sensory fai-
lure.
Internal supervision is applied on
several levels. First of all the computer is
equipped with certain control functions,
known as ÒwatchdogsÒ. These supervise
that the computer does not make obvious
calculation errors. In addition the wind
Cup anemometer for wind speed indication (left) ¥ Lightning conductor (middle) ¥ Wind direction indicator (right)
turbine software itself has extra control the blade rotational speed and activate
functions. For example in the case of the braking systems, even if the speed
wind speed parameters. A wind turbine measurement system of the controller
is designed to operate at wind speeds up should fail.
to 25 m/s, and the signal from the A 600 kW Mk IV wind turbine has
anemometer (wind speed indicator) is two centrifugal release units. One of
used in taking the decision to stop the these is hydraulic and placed on the
wind turbine, as soon as the wind speed wind turbine hub. It is normally called a
exceeds 25 m/s. CU (Centrifugal release Unit). Should
As a control function of the the wind turbine operate at too high a
anemometer the controller supervises rotational speed, a weight will be thrown
wind speed in relation to power. The out and thereby open a hydraulic valve.
controller will stop the wind turbine and
indicate a possible wind measurement
error, if too much power is produced
during a period of low wind, or too little
power during a period of high wind.
A wind measurement error could be
caused by a fault in the electrical wiring,
or a defect bearing in the anemometer.
A constant functional check of the
relationship between wind speed and
power production ensures that it is almost
impossible for the wind turbine
to continue operation with a wind
measurement error, and the possibility
of a wind turbine being subject to
stronger winds than its designed wind
speed rating, is therefore more or less
eliminated.
The third safety principle for the
controller lies in duplication of systems.
A good example is the mechanical
centrifugal release units. These supervise Interior view of the CU
23
Once the valve is open, hydraulic oil will
spill out from the hydraulic cylinders that
hold the blade tips in place, thereby
activating the blade tip air brakes.
No matter what actions the controller or
the hydraulic system thereafter attempts
to carry out, pressure cannot be maintai-
ned in the cylinders and the air brakes
will continue to remain activated, until a
serviceman resets the centrifugal release
manually.
The advantages of the hydraulic
centrifugal release units is that it is
completely independent the controller
and the hydraulic system. This ensures
that a possible fatal software design
error, not discovered during design
review, will not result in a possible
run-away of the wind turbine.
The second centrifugal release unit is
an electro-mechanical unit, fixed to the
high speed shaft of the gearbox. This is
normally called an HCU, where H is
short for Òhigh-speedÓ. Should the wind
turbine over-speed, two small arms are
thrown out mechanically cutting off the
electrical current to the magnetic valves
of the air brakes and the mechanical
braking system.
This is a so-called fail-safe system,
where the electrical circuit must remain
HCU placed on the high speed shaft of the gearbox
switched on in order to maintain the
valves for the air brakes and for the
mechanical brake in a closed position.
Should the electrical circuit be broken
because of a disconnection from the grid
or as a result of a shut down from the con-
troller itself, the valves will open and
activate the brakes causing the wind
turbine to slow down and stop.
The HCU is able to mechanically cut
the braking circuit, and thereby activate
both braking systems. The hub-mounted
CU only cuts the blade hydraulic system.
The HCU therefore is superior, however
its successful operation is based in turn
upon satisfactory operation of the normal
valve systems, while the CU has its own
extra valve system. Both systems thus
have their own advantages and dis-
advantages considered from the point of
view of safety.
Both centrifugal release units are
adjusted to be activated at very near
the normal operational rotational speed,
therefore, on rare occasions, release
can occur prematurely. This is not
normally the case in Denmark, but
following from unexpected power cuts at
certain foreign projects, causing the
turbines shortly to operate in stand-alone
mode, we have experienced release
activation. Otherwise centrifugal release
systems are only intended to be activated
during maintenance testing.
HYDRAULICS
The controller decides which operations
are to be carried out in the safety system,
while the hydraulic system operates the
braking systems.
In a hydraulic system a liquid under
pressure is used to move certain com-
ponents. This liquid is called hydraulic
oil, having a resemblance to lubricating
oil. The operating pressure is about
1.000 Bar (one Bar is equivalent to one
atmosphere). The moving components
are pistons in hydraulic cylinders. With a
pressure of 100 Bar a piston in a 50 mm
hydraulic cylinder (similar to the units
used in pulling the blade tips into
position) produces a force of 2 tons.
The hydraulic systems of both the tip-
brakes and the mechanical brake are also
fail-safe systems, i.e. hydraulic pressure
is necessary for the wind turbine to
operate. The hydraulic system ensures
that pressure is established when the
wind turbine starts. It also releases the
pressure when the turbine must stop.
Pressure is built up with a pump
controlled by a pressure sensitive switch.
Following attainment of the required
pressure level, occasional operation of
the pump maintains the level. A reserve
pressure tank is also included in the
system. This small steel tank contains a
rubber membrane separating the hydrau-
lic oil from an enclosed body of air.
When the oil is under pressure, this will
press against this body of air, which in
turn will act as a kind of cushion giving
a counter pressure, thereby enabling the
pressure in the whole system to be
maintained.
The release of pressure from the tip-
brakes and the mechanical brake is
carried out by the means of magnetic
valves. These are held in a closed
position by the use of an electromagnet
and will automatically open with a lack
of electrical current. They are therefore
operated by being simply switched off.
In order to avoid operational failure
problems that any one specific make of
valve could possibly produce, two
different makes of valves from two diffe-
rent manufacturers are placed in parallel
24

in each of the two different systems for

both air brakes and the mechanical brake.
Secure and safe operation is ensured even
with only one single operational valve,
and their functioning is checked at every
routine maintenance schedule.
In addition the mechanical hydraulic
CU is fixed at the hub of the rotor blade
itself. This unit is completely indepen-
dent of the functioning of the magnetic
valves in releasing the pressure in the air
brake hydraulic cylinders.

TIP BRAKES
The moveable blade tips on the outer
2.8 meters of the blades function as air Tip brake in function
brakes, usually called tip brakes.
The blade tip is fixed on a carbon point 1 in the section dealing with hydraulic oil pressure is necessary to
fiber shaft, mounted on a bearing inside problems - to prevent the blades having a prevent the brake unit from braking.
the main body of the blade. On the end of greatly increased power production with Should oil pressure be lacking, a
the shaft inside the main blade, a con- increased rotational speed. They cannot powerful spring presses the brake blocks
struction is fixed, which rotates the blade however normally completely stop blade in against the brake disc.
tip if subject to an outward movement. rotation, and therefore for every wind Braking is a result of friction between
The shaft also has a fixture for a steel speed there is a corresponding free- the brake block and the disc. Wind
wire, running the length of the blade wheeling rotational speed. However even turbine brakes experience large stress
from the shaft to the hub, enclosed inside for the highest wind speeds experienced forces, therefore it is necessary to use
a hollow tube. in Denmark, the free-wheeling rotational special materials for brake blocks on
During operation the tip is held fast speed is much lower than the normal large wind turbines. These are made of
against the main blade by a hydraulic operational rotational speed, so the wind a special metal alloy, able to function
cylinder inside the hub, pulling with a turbine is in a secure condition, even if under high temperatures of up to
force of about 1 ton on the steel wire the mechanical brake should possibly 700 degrees Centigrade. By comparison,
running from the hub to the blade tip fail. the temperature of the brakes on a car
shaft. rarely exceed 300 degrees.
When it is becomes necessary to stop THE MECHANICAL BRAKE The mechanical brake function is
the wind turbine, the restraining power is The Mechanical brake is a disc brake as described under point 2 of the
cut-off by the release of oil from the placed on the gearbox high-speed shaft. section dealing with the possible
hydraulic cylinder, thereby permitting The brake disc, made of steel, is fixed to problem situations - to prevent the
centrifugal force to pull the blade tip the shaft. The component that does the rotational speed of the blades from
outwards. The mechanism on the tip shaft actual braking is called the brake caliper. increasing above the rated rotational
then rotates the blade tip through 90 Likewise this is also a fail-safe system, speed.
degrees, into the braking position. The
hydraulic oil outflow from the hydraulic
cylinder escapes through a rather small
hole, thus allowing the blade tip to turn
slowly for a couple of seconds before it is
fully in position. This thereby avoids
excessive shock loads during braking.
As previously described in the section
on the hydraulic system, the construction
set-up is fail-safe requiring an active
component (oil pressure) in order to keep
the turbine in an operational mode, while
a missing active component (no oil
pressure) activates the system.
The tip brakes effectively stop the dri-
ving force of the blades. They therefor
The Mechanical Brake
have the function as described under
 ¨

BONUS Energy A/S

A/S reg. nr. 67.911
Fabriksvej 4 ¥ box 170
7330 Brande
Tlf: 97 18 11 22
Fax: 97 18 30 86
E-mail: bonus@bonus.dk
Web: www.bonus.dk